Porosity reference standard utilizing one or more discrete wires

Abstract

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which may substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness and at least one discrete wire. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The discrete wire may scatter and attenuate ultrasonic energy. The reference standard may replace more costly, porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

1. An ultrasonic inspection reference standard for composite materials having porosity, comprising: a member having at least one thickness, wherein said member is manufactured from a fiber-free photo-polymer resin; and a plurality of spaced-apart discrete wires disposed within or against the member. 
   
   
     2. The ultrasonic inspection reference standard of  claim 1 , wherein said photo-polymer resin comprises substantially similar ultrasonic properties of a composite material. 
   
   
     3. The ultrasonic inspection reference standard of  claim 1 , wherein said member comprises more than one thickness. 
   
   
     4. The ultrasonic inspection reference standard of  claim 1 , wherein said member is created using a 3D computer-aided-design model. 
   
   
     5. The ultrasonic inspection reference standard of  claim 1 , wherein said at least one thickness of said member comprises substantially similar ultrasonic properties of a thickness of a composite material. 
   
   
     6. The ultrasonic inspection reference standard of  claim 1 , wherein said member is manufactured using a stereo lithography process. 
   
   
     7. The ultrasonic inspection reference standard of  claim 1 , wherein said reference standard comprises substantially similar ultrasonic properties of a composite material having porosity. 
   
   
     8. The ultrasonic inspection reference standard of  claim 7 , wherein one or more of the type, diameter, location, size, and spacing of said plurality of spaced-apart discrete wires provides the ultrasonic inspection reference standard with substantially similar ultrasonic properties of a composite material having porosity. 
   
   
     9. The ultrasonic inspection reference standard of  claim 1 , wherein said ultrasonic reference standard is for graphite epoxy composite materials having porosity. 
   
   
     10. The ultrasonic inspection reference standard of  claim 1 , wherein said member is defined by a plurality of shafts in which said plurality of spaced-apart discrete wires are positioned. 
   
   
     11. The ultrasonic inspection reference standard of  claim 1 , wherein said plurality of spaced-apart discrete wires are unconnected. 
   
   
     12. The ultrasonic inspection reference standard of  claim 11 , wherein said member is defined by a plurality of internal shafts in which said plurality of unconnected, spaced-apart discrete wires are disposed. 
   
   
     13. The ultrasonic inspection reference standard of  claim 11 , wherein one or more of the type, location, diameter, and spacing of said plurality of unconnected, discrete spaced-apart wires provides said reference standard with substantially similar ultrasonic properties of a composite material having porosity. 
   
   
     14. The ultrasonic inspection reference standard of  claim 1 , wherein said reference standard is for the inspection of a fiber-reinforced composite part of an aircraft structure. 
   
   
     15. An ultrasonic inspection reference standard for composite materials having porosity, comprising: a member having at least one thickness, wherein said member was manufactured using a stereo lithography process; and a plurality of spaced-apart discrete wires disposed within or against the member, wherein said reference standard has substantially similar ultrasonic properties of a fiber-reinforced composite part having porosity. 
   
   
     16. The ultrasonic inspection reference standard of  claim 15 , wherein said member is manufactured from a fiber-free polymer resin. 
   
   
     17. The ultrasonic inspection reference standard of  claim 15 , wherein said member is defined by a plurality of shafts in which said plurality of spaced-apart discrete wires are disposed. 
   
   
     18. The ultrasonic inspection reference standard of  claim 17 , wherein one or more of the type, location, diameter, and spacing of said plurality of spaced-apart discrete wires provides said reference standard with substantially similar ultrasonic properties of a composite part having porosity. 
   
   
     19. The ultrasonic inspection reference standard of  claim 15 , wherein said reference standard contains the ultrasonic properties of a graphite-epoxy reference standard. 
   
   
     20. The ultrasonic inspection reference standard of  claim 18 , wherein said member is manufactured from a fiber-free photo-polymer resin. 
   
   
     21. The ultrasonic inspection reference standard of  claim 15 , wherein said reference standard is for the inspection of a fiber-reinforced composite part of an aircraft structure.